Magnetic element

Abstract

A magnetic element comprises a magnetic core, a first winding, a second winding and at least one magnetic filler. The magnetic core comprises an inner column. The first winding is arranged in the magnetic core and wound on the inner column. The second winding is arranged in the magnetic core and surrounds the first winding. At least one filling area and at least one non-filling area are formed between the first winding and the second winding. The at least one magnetic filler is filled in at least a portion of the at least one filling region.

Description

Technical Field

[0001] The present invention relates to a magnetic element, and more particularly to a magnetic element capable of effectively increasing leakage inductance. Background Art

[0002] A circuit architecture configured with a multi-phase trans-inductor can achieve fast dynamic response. Since the leakage inductance of the multi-phase trans-inductor is insufficient, an additional inductor needs to be connected in series with the multi-phase trans-inductor to increase the leakage inductance. However, the additional inductor increases the manufacturing cost and occupies additional space on the motherboard. Summary of the invention

[0003] The present invention provides a magnetic element which can effectively increase leakage inductance to solve the above problems.

[0004] According to one embodiment, the magnetic element of the present invention comprises a magnetic core, a first winding, a second winding and at least one magnetic filler. The magnetic core comprises an inner column. The first winding is disposed in the magnetic core and wound around the inner column. The second winding is disposed in the magnetic core and surrounds the first winding. At least one filling area and at least one non-filling area are formed between the first winding and the second winding. At least one magnetic filler is filled in at least a portion of at least one filling area.

[0005] In one embodiment, a gap of at least one filled region is larger than a gap of at least one non-filled region.

[0006] In one embodiment, a gap of at least one filled region is greater than or equal to three times a gap of at least one non-filled region.

[0007] In one embodiment, a gap of at least one filling region is greater than or equal to 0.5 mm.

[0008] In one embodiment, the magnetic core includes a first core and a second core, the first winding and the second winding are located between the first core and the second core, and at least one magnetic filler does not contact the first core and the second core at the same time.

[0009] In one embodiment, at least one magnetic filler is made of magnetic glue.

[0010] In one embodiment, at least one magnetic filler is a magnetic block.

[0011] In one embodiment, at least one magnetic filler is integrally formed with the magnetic core.

[0012] In one embodiment, the magnetic core includes a first core body and a second core body, the first winding and the second winding are located between the first core body and the second core body, and at least one magnetic filler includes a first protrusion and a second protrusion opposite to each other, the first protrusion protrudes from the first core body, and the second protrusion protrudes from the second core body.

[0013] In one embodiment, the magnetic core includes at least one air gap, the magnetic element further includes at least one air gap filler, and the at least one air gap filler fills the at least one air gap.

[0014] In one embodiment, at least one air gap filler is made of magnetic material.

[0015] In one embodiment, at least one air gap filler is made of non-magnetic material.

[0016] In one embodiment, the first winding includes a first top and two first sides, the first top is connected between the two first sides, the second winding includes a second top and two second sides, the second top is connected between the two second sides, the first top corresponds to the second top, and the two first sides correspond to the two second sides.

[0017] In one embodiment, at least one filling region is located between the first top portion and the second top portion, and at least one non-filling region is located between the two first side portions and the two second side portions.

[0018] In one embodiment, at least one filling region is located between the two first side portions and the two second side portions, and at least one non-filling region is located between the first top portion and the second top portion.

[0019] In one embodiment, the first winding and the second winding define a boundary of at least one filling region.

[0020] In one embodiment, the at least one magnetic filler is filled to the boundary of the at least one filling region.

[0021] In one embodiment, at least one magnetic filler contacts the first winding and the second winding.

[0022] In summary, the present invention fills the filling area between the first winding and the second winding with magnetic filler, and can effectively increase the leakage inductance of the magnetic element without excessively increasing the height of the magnetic element. Thus, the magnetic element can be applied to a DC-to-DC converter to provide sufficient leakage inductance without connecting an additional inductor in series. Therefore, the manufacturing cost can be reduced, and the space on the motherboard will not be occupied by the additional inductor.

[0023] The advantages and spirit of the present invention can be further understood through the following detailed description of the invention and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 FIG. 4 is a three-dimensional diagram of a magnetic element according to an embodiment of the present invention.

[0025] Figure 2 for Figure 1 Exploded view of the magnetic components in .

[0026] Figure 3 for Figure 1 Cross-sectional view of the magnetic component in FIG.

[0027] Figure 4 for Figure 1 Another cross-sectional view of the magnetic element in FIG.

[0028] Figure 5 for Figure 1 Side view of the magnetic core in FIG.

[0029] Figure 6 FIG. 4 is a cross-sectional view of a magnetic element according to another embodiment of the present invention.

[0030] Figure 7 FIG. 4 is a cross-sectional view of a magnetic element according to another embodiment of the present invention.

[0031] Figure 8 It is a cross-sectional view of different types of magnetic fillers filled in the filling area.

[0032] The reference numerals are described as follows:

[0033] 1: Magnetic components

[0034] 10: Magnetic core

[0035] 10a: First core

[0036] 10b: Second core

[0037] 12: First winding

[0038] 14: Second winding

[0039] 16: Magnetic filler

[0040] 16a: First protruding member

[0041] 16b: Second protruding piece

[0042] 18: Air gap filler

[0043] 100: Inner column

[0044] 102: Outer column

[0045] 104: Air Gap

[0046] 120: First Top

[0047] 122: First side

[0048] 140: Second top

[0049] 142: Second side

[0050] G1, G2: Clearance

[0051] FR: Filling area

[0052] NFR: Non-Filled Region

[0053] X,Y: Hatch Line DETAILED DESCRIPTION

[0054] See also Figures 1 to 4 , Figure 1 is a three-dimensional diagram of a magnetic element 1 according to an embodiment of the present invention, Figure 2 for Figure 1 Exploded view of magnetic component 1 in Figure 3 for Figure 1 The cross-sectional view of the magnetic element 1 along the XX line, Figure 4 for Figure 1 Another cross-sectional view of the magnetic element 1 along line YY.

[0055] like Figures 1 to 4 As shown, the magnetic element 1 of the present invention comprises a magnetic core 10, a first winding 12, a second winding 14 and at least one magnetic filler 16. The magnetic element 1 can be a trans-inductor, a coupling choke or other magnetic elements, depending on the actual application.

[0056] The magnetic core 10 includes an inner column 100. The first winding 12 is disposed in the magnetic core 10 and wound around the inner column 100. The second winding 14 is disposed in the magnetic core 10 and surrounds the first winding 12. In the present embodiment, the magnetic core 10 may include a first core 10a and a second core 10b. Both the first core 10a and the second core 10b may be E-type magnetic cores. The effective magnetic field strength of the two E-type magnetic cores is similar, which can effectively improve the efficiency of the component. In addition, the two E-type magnetic cores and the windings can be fixed to each other in a mechanical manner, which can increase the strength and reduce the chance of falling. In another embodiment, one of the first core 10a and the second core 10b may be an E-type magnetic core, and one of the first core 10a and the second core 10b may be an I-type magnetic core. The types of the first core 10a and the second core 10b can be determined according to actual applications, and the present invention is not limited to the embodiments shown in the figures. In one embodiment, the inner column 100 can be integrally formed with the first core 10a or the second core 10b. In another embodiment, the inner column 100 can be divided into two sections, which are integrally formed with the first core member 10a and the second core member 10b respectively. When the magnetic core 10 is composed of the first core 10a and the second core 10b, the first winding 12 and the second winding 14 are located between the first core 10a and the second core 10b.

[0057] like Figure 3 As shown, the second winding 14 is spaced apart from the first winding 12, so that at least one filling region FR and at least one non-filling region NFR are formed between the first winding 12 and the second winding 14. Therefore, the first winding 12 and the second winding 14 define the boundary of at least one filling region FR. In this embodiment, a filling region FR and two non-filling regions NFR are defined between the first winding 12 and the second winding 14. In this embodiment, the first winding 12 may include a first top 120 and two first side portions 122. The first top 120 is connected between the two first side portions 122. In addition, the second winding 14 may include a second top 140 and two second side portions 142. The second top 140 is connected between the two second side portions 142. When the first winding 12 and the second winding 14 are disposed in the magnetic core 10, the first top 120 corresponds to the second top 140, and the two first side portions 122 correspond to the two second side portions 142. Therefore, the filling region FR is located between the first top portion 120 and the second top portion 140 , and the two non-filling regions NFR are located between the two first side portions 122 and the two second side portions 142 .

[0058] like Figure 3As shown, a magnetic filler 16 is filled in at least a portion of the filling region FR. In this embodiment, the magnetic filler 16 can be filled to the boundary of the filling region FR so that the magnetic filler 16 can contact the first winding 12 and the second winding 14. The magnetic filler 16 can be made of magnetic glue, but is not limited to this. The advantage of magnetic glue is that the production line can adjust the amount of magnetic glue to adjust the required properties. In another embodiment, the magnetic filler 16 can be a magnetic block that is individually filled in the filling region FR. The advantage of the magnetic block is that the process is simple, and the magnetic block only needs to be placed in the desired position.

[0059] In addition, the gap G1 of the filling area FR may be greater than the gap G2 of the non-filling area NFR. Since the second winding 14 and the first winding 12 are separated by the gap G1 of the filling area FR and the gap G2 of the non-filling area NFR, and the magnetic filler 16 is filled in the filling area FR, the leakage inductance of the magnetic element 1 can be effectively increased without excessively increasing the height of the magnetic element 1. In one embodiment, the gap G1 of the filling area FR may be greater than or equal to three times the gap G2 of the non-filling area NFR, that is, G1≥3*G2, to further enhance the leakage inductance of the magnetic element 1. In another embodiment, the gap G1 of the filling area FR may be greater than or equal to 0.5 mm, to further enhance the leakage inductance of the magnetic element 1.

[0060] like Figure 4 As shown, the magnetic filler 16 may not contact the first core 10a and the second core 10b at the same time to avoid affecting the magnetic permeability between the first winding 12 and the second winding 14 and to avoid affecting the leakage inductance path. In this embodiment, the magnetic filler 16 may contact the second core 10b and not contact the first core 10a, but is not limited thereto. In another embodiment, the magnetic filler 16 may contact the first core 10a and not contact the second core 10b, depending on the actual application.

[0061] See also Figure 5 , Figure 5 for Figure 1 1 is a side view of the magnetic core 10.

[0062] like Figure 5As shown, the magnetic core 10 may include at least one outer column 102 and at least one air gap 104. In the present embodiment, the magnetic core 10 may include two outer columns 102 and three air gaps 104. The three air gaps 104 are formed in the inner column 100 and the two outer columns 102, respectively. It should be noted that the number and position of the outer columns 102 and the air gaps 104 may be determined according to the actual application, and the present invention is not limited to the embodiments shown in the figure. In addition, the magnetic element 1 may further include at least one air gap filler 18, and at least one air gap filler 18 is filled in at least one air gap 104. At least one air gap filler 18 may be made of a magnetic material or a non-magnetic material. For example, the air gap filler 18 may be made of a non-magnetic material, such as air, insulating glue, insulating paper, etc., or alternatively, the air gap filler 18 may include, but is not limited to, a glue material with magnetic powder, a separately added magnetic block, or a protruding structure integrally formed with the magnetic core 10. The air gap 104 with the air gap filler 18 can make the magnetic field strength more balanced and achieve better saturation and efficiency.

[0063] See also Figure 6 , Figure 6 is a cross-sectional view of a magnetic element 1 according to another embodiment of the present invention.

[0064] like Figure 6 As shown, at least one magnetic filler 16 may be integrally formed with the magnetic core 10. For example, at least one magnetic filler 16 may include a first protrusion 16a and a second protrusion 16b opposite to each other. The first protrusion 16a protrudes from the first core 10a toward the second core 10b, and the second protrusion 16b protrudes from the second core 10b toward the first core 10a. The first protrusion 16a may not contact the second protrusion 16b, so that there is a gap between the first protrusion 16a and the second protrusion 16b. The advantage of integrally forming the protrusion and the magnetic core is that the assembly is simple, and it is only necessary to control the air gap of the main inductance.

[0065] See also Figure 7 , Figure 7 is a cross-sectional view of a magnetic element 1 according to another embodiment of the present invention.

[0066] like Figure 7 As shown, at least one filling region FR may be located between the two first side portions 122 of the first winding 12 and the two second side portions 142 of the second winding 14, and at least one non-filling region NFR may be located between the first top portion 120 of the first winding 12 and the second top portion 140 of the second winding 14. In this embodiment, the two filling regions FR are located between the two first side portions 122 and the two second side portions 142, and the non-filling region NFR is located between the first top portion 120 and the second top portion 140. In addition, the two magnetic fillers 16 are filled in at least a portion of the two filling regions FR. In this embodiment, the magnetic fillers 16 may be filled to the boundary of the filling region FR, so that the magnetic fillers 16 may contact the first winding 12 and the second winding 14.

[0067] See also Figure 8 , Figure 8 1 is a cross-sectional view of different types of magnetic fillers 16 filled in the filling region FR.

[0068] like Figure 8 As shown, the magnetic filler 16 filled in the filling area FR to increase the leakage inductance is not limited to a single shape, position or quantity. The proportion of the magnetic filler 16 occupying the filling area FR to form the leakage inductance path can be the magnetic filler 16 connected in series with the air and the magnetic core, or the magnetic filler 16 connected in parallel with the air and then in series with the magnetic core. The magnetic filler 16 can be arranged in different shapes on the leakage inductance path, and the magnetic permeability of the magnetic filler 16 can be less than the magnetic permeability of the magnetic core.

[0069] In summary, the present invention fills the filling area between the first winding and the second winding with magnetic filler, and can effectively increase the leakage inductance of the magnetic element without excessively increasing the height of the magnetic element. Thus, the magnetic element can be applied to a DC-to-DC converter to provide sufficient leakage inductance without connecting an additional inductor in series. Therefore, the manufacturing cost can be reduced, and the space on the motherboard will not be occupied by the additional inductor.

[0070] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made according to the claims of the present invention should fall within the scope of the present invention.

Claims

1. A magnetic element, comprising: a magnetic core including an inner column; a first winding disposed in the magnetic core and wound around the inner column; a second winding disposed in the magnetic core and surrounding the first winding, wherein at least one filling area and at least one non-filling area are formed between the first winding and the second winding; and At least one magnetic filler is filled in at least a portion of the at least one filling area. 2 . The magnetic element as claimed in claim 1 , wherein a gap of the at least one filling region is larger than a gap of the at least one non-filling region. 3 . The magnetic element as claimed in claim 2 , wherein a gap of the at least one filling region is greater than or equal to three times a gap of the at least one non-filling region. The magnetic element as claimed in claim 1 , wherein a gap of the at least one filling region is greater than or equal to 0.5 mm. 5 . The magnetic element as claimed in claim 1 , wherein the magnetic core comprises a first core and a second core, the first winding and the second winding are located between the first core and the second core, and the at least one magnetic filler does not contact the first core and the second core at the same time. The magnetic element as claimed in claim 1 , wherein the at least one magnetic filler is made of magnetic glue. The magnetic element as claimed in claim 1 , wherein the at least one magnetic filler is a magnetic block. The magnetic element as claimed in claim 1 , wherein the at least one magnetic filler is integrally formed with the magnetic core.

9. A magnetic element as described in claim 1, wherein the magnetic core includes a first core body and a second core body, the first winding and the second winding are located between the first core body and the second core body, and the at least one magnetic filler includes a first protrusion and a second protrusion opposite to each other, the first protrusion protrudes from the first core body, and the second protrusion protrudes from the second core body. 10 . The magnetic element as claimed in claim 1 , wherein the magnetic core comprises at least one air gap, the magnetic element further comprises at least one air gap filler, and the at least one air gap filler fills the at least one air gap. The magnetic element as claimed in claim 10 , wherein the at least one air gap filler is made of a magnetic material. 12 . The magnetic element as claimed in claim 10 , wherein the at least one air gap filler is made of a non-magnetic material.

13. A magnetic element as described in claim 1, wherein the first winding includes a first top and two first sides, the first top is connected between the two first sides, the second winding includes a second top and two second sides, the second top is connected between the two second sides, the first top corresponds to the second top, and the two first sides correspond to the two second sides. 14 . The magnetic element as claimed in claim 13 , wherein the at least one filling region is located between the first top portion and the second top portion, and the at least one non-filling region is located between the two first side portions and the two second side portions. 15 . The magnetic element as claimed in claim 13 , wherein the at least one filling region is located between the two first side portions and the two second side portions, and the at least one non-filling region is located between the first top portion and the second top portion. 16 . The magnetic element of claim 1 , wherein the first winding and the second winding define a boundary of the at least one filling region. 17 . The magnetic element as claimed in claim 16 , wherein the at least one magnetic filler is filled to a boundary of the at least one filling region. 18 . The magnetic element as claimed in claim 17 , wherein the at least one magnetic filler contacts the first winding and the second winding.

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